Multiphase contact and distribution apparatus for hydroprocessing

ABSTRACT

Systems and apparatus for mixing, cooling, and distributing multiphase fluid mixtures within a reactor, wherein reactor internal apparatus of the present invention provides not only improved fluid mixing and distribution to each underlying catalyst bed surface, but also offers other advantages including: decreased mixing tray height; easier maintenance, assembly and disassembly; and decreased amounts of fabrication material. In an embodiment, fluid may be evenly distributed to a catalyst bed from a fluid distribution unit comprising a nozzle tray including a plurality of nozzles, wherein the nozzles include at least one liquid inlet disposed tangentially to an inner surface of the nozzle.

This application is a divisional of co-pending U.S. Ser. No. 12/839,222filed Jul. 19, 2010, herein incorporated by reference.

FIELD OF THE INVENTION

This invention relates to systems and apparatus for multiphase fluidcontact and distribution.

BACKGROUND OF THE INVENTION

Many catalytic processes are performed in reactors containing a seriesof separate catalytic beds. Reactors used in the chemical, petroleumrefining, and other industries for passing liquids or mixed-phaseliquid/gas mixtures over packed beds of particulate solids are employedfor a variety of different processes. Examples of such processesinclude: catalytic dewaxing, hydrotreating, hydrodesulphurization,hydrofinishing, and hydrocracking. In these processes a liquid phase istypically mixed with a gas or vapor phase and the mixture passed over aparticulate catalyst in a packed bed within a downflow reactor.

In downflow reactors, it is necessary that the gas and liquid areproperly mixed and uniformly distributed across the horizontal crosssection of the reactor prior to contacting each catalyst bed. Suchuniform distribution of the gas and liquid provides major advantages,including: efficient utilization of catalyst, reduced catalyst top layerattrition, improved yields, improved product quality, and increased runlengths. Generally in a downflow catalytic reactor, a plurality ofcatalyst beds are arranged within the reactor, and a distributor systemfor the efficient mixing of gas and liquids is disposed above eachcatalyst bed. The region between catalyst beds is normally provided witha gas injection line to provide additional gas to compensate for gasconsumed in the previous catalyst bed. The injected gas can also act asa quench gas for cooling the feed exiting a catalyst bed prior to thefeed entering the next catalyst bed. Generally, the injected gas ishydrogen or comprises hydrogen. The liquid feed falling from theabove-lying catalyst bed is allowed to accumulate on a collection tray.The quench gas and liquid then pass into a mixing chamber where aswirling movement of the liquid is provided. This enables good mixing ofthe liquid and thereby provides even temperature conditions of theliquid. Gas-liquid mixing also takes place inside the mixing chamber.

The fluid from the mixing chamber flows downward onto a deflector orimpingement plate, whereby the flow is redirected onto a distributortray having a large number of downflow openings for the passage ofliquid. For cross-sectional liquid flow distribution, the downflowopenings of conventional apparatus can comprise one or more conduits, orchimneys. The chimney is a cylindrical structure with an open top andone or more openings in the upper portion of its height through which agas phase can enter. The gas phase travels downward through the lengthof the chimney. The lower portion of the chimney can have one or morelateral openings for liquid flow through which a liquid phase can enterthe chimney and contact the gas phase. As liquid continues to accumulateon the distributor tray, the liquid will rise to a level that covers thelateral opening(s) in the chimney so that the passage of gas isprecluded and so that the liquid can enter through the lateralopening(s) into the chimney. Gases and liquids egress via an opening inthe bottom of the chimney, through the distributor tray, and onto anunderlying catalyst bed. A disadvantage of conventional conduits orchimneys is that, due to the low turbulence around liquid streams, onlylimited mixing between the two phases will occur.

A good flow distribution device for a catalytic reactor should meet thefollowing four basic requirements: provide even distribution of feed toa catalyst bed over a range of gas and liquid feed rates; be tolerant tocertain out-of-levelness of the distribution tray; provide goodgas-liquid mixing and heat exchange, and require minimum catalyst bedheight to fully wet the underlying catalyst bed. Because conventionalchimneys rely on the static liquid height on the tray as the drivingforce for liquid flow into the chimney, they are deficient in meetingthese criteria due to poor tolerance for deviations from levelness ofthe distributor tray, as well as exhibiting suboptimal spray dischargeof fluids onto the underlying catalyst bed, and other deficiencies.

One of the key considerations in flow distributor design is thedischarge pattern of liquid and gas from the device. A conventionalchimney distributor provides a limited number of points of contact ofthe liquid feed with the catalyst bed. As a result, a larger distancefrom the chimney to the bed is required to wet the catalyst surface.

U.S. Pat. No. 7,473,405 to Kemoun et al. discloses a nozzle device forcoupling with a fluid distribution conduit.

There is a continuing need for hydroprocessing reactor apparatusproviding improved hydrogen/oil mixing at the mixing tray, more uniformand consistent liquid distribution on the catalyst bed, a decreasedmixing tray height, and decreased amounts of fabrication material, aswell as easier maintenance, assembly and disassembly. There is also aneed for systems and apparatus that provide improved tolerance fordistributor tray out-of-levelness conditions. There is still a furtherneed for fluid distribution apparatus that can provide more uniformdistribution of liquid on a catalyst bed under liquid-only conditions.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided areactor system comprising a reactor shell, a primary feed distributionunit disposed within the reactor shell, and at least one secondary feeddistribution unit disposed beneath the primary feed distribution unitwithin the reactor shell. The primary feed distribution unit comprises aprimary deflector plate and a first nozzle tray disposed beneath thedeflector plate. The at least one secondary feed distribution unitcomprises a collection tray and a second nozzle tray disposed beneaththe collection tray. Each of the first nozzle tray and the second nozzletray comprises a plurality of nozzles, the nozzles each comprise anozzle body including a distal body portion having at least one liquidinlet configured for the passage of liquid therethrough. The distal bodyportion defines a substantially cylindrical distal void. Each liquidinlet is disposed tangentially to an inner surface of the distal bodyportion.

In an embodiment, the present invention also provides a reactor systemcomprising a reactor shell having an inner wall, a primary feeddistribution unit disposed within the reactor shell, and at least onesecondary feed distribution unit disposed beneath the primary feeddistribution unit within the reactor shell. Each secondary feeddistribution unit comprises a collection tray, a nozzle tray disposedbeneath the collection tray, at least one support ring affixed to thereactor shell inner wall, and a plurality of trusses. Each truss spansthe at least one support ring. Each truss has an upper flange and alower flange, the upper flange supports the collection tray and thelower flange supports the nozzle tray.

In another embodiment of the present invention, there is provided a feeddistribution unit for a catalytic reactor, the feed distribution unitcomprising a deflector plate and a nozzle tray disposed beneath thedeflector plate. The nozzle tray includes a plurality of nozzles. Eachnozzle comprises a nozzle body including a distal body portion having atleast one liquid inlet configured for the passage of liquidtherethrough. The distal body portion defines a substantiallycylindrical distal void. Each liquid inlet is disposed tangentially toan inner surface of the distal body portion.

In an embodiment, the present invention further provides a nozzle forthe even distribution of a multi-phase fluid mixture, the nozzlecomprising a nozzle body having a proximal body portion, an intermediatebody portion, and a distal body portion. The proximal body portiondefines a substantially cylindrical proximal void, and the proximal bodyportion has at least one gas inlet configured for the passage of gastherethrough into the proximal body portion. The intermediate bodyportion defines a substantially cylindrical intermediate void in fluidcommunication with the proximal void. The distal body portion has a bodywall and at least one liquid inlet configured for the passage of liquidtherethrough into the distal body portion. The distal body portiondefines a substantially cylindrical distal void, and the at least oneliquid inlet is disposed tangentially to an inner surface of the distalbody portion.

In another embodiment of the present invention, there is provided afluid distribution apparatus for a reactor, the apparatus comprising anozzle tray; a plurality of chimneys affixed to, and extending through,the nozzle tray; and a fluid distribution nozzle disposed within eachchimney. Each chimney has a chimney wall defining a substantiallycylindrical void extending substantially vertically from a lower surfaceof the nozzle tray to a location above an upper surface of the nozzletray. The chimney has an open proximal end and an open distal end, andthe chimney wall has at least one lateral opening therein. The nozzlecomprises a nozzle body comprising a proximal body portion, anintermediate body portion, and a distal body portion having a distalbody wall. The proximal body portion defines a substantially cylindricalproximal void, and the open proximal end is configured for the passageof gas therethrough. The intermediate body portion defines asubstantially cylindrical intermediate void in fluid communication withthe proximal void. The distal body portion has a liquid inlet configuredfor the passage of liquid therethrough into the distal body portion. Thedistal body portion defines a substantially cylindrical distal void. Theliquid inlet comprises a curved channel within the distal body wall, andthe curved channel has an inner terminus disposed tangentially to aninner surface of the distal body portion.

In another embodiment, the present invention still further provides afluid distribution device comprising a substantially cylindrical hollownozzle body having a plurality of outer slots disposed circumferentiallyaround the nozzle body; a cap affixed to a proximal portion of thenozzle body, the cap having an axial proximal opening therein; a baseaffixed to a distal portion of the nozzle body, the base having an axialdistal opening therein; and a substantially cylindrical inner conduitdisposed axially within a proximal portion of the nozzle body. The innerconduit is disposed within the proximal opening of the cap, and theinner conduit extends proximally from the cap to define a proximal endof the inner conduit. The inner conduit has a plurality of inner slotsdisposed circumferentially around the proximal end of the inner conduit.A distal end of the inner conduit extends distally to a locationproximal to a distal end of each of the outer slots.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram schematically representing a reactor system,according to an embodiment of the present invention;

FIG. 2 is a block diagram schematically representing a catalytic unitfor a reactor system, according to an embodiment of the presentinvention;

FIG. 3 is a block diagram schematically representing a reactor system,according to another embodiment of the present invention;

FIG. 4A is a block diagram schematically representing a primary feeddistribution unit, according to an embodiment of the present invention;

FIG. 4B is a block diagram schematically representing a secondary feeddistribution unit, according to an embodiment of the present invention;

FIG. 5A shows a schematic cut-away view of a portion of a reactor shellwith associated reactor internal apparatus, according to an embodimentof the present invention;

FIG. 5B is a plan view of a feed distribution unit as seen along thelines 5B-5B of FIG. 5A and showing a plurality of collection traysegments;

FIG. 5C is a plan view of a portion of the feed distribution unit ofFIG. 5B with the collection tray segments removed and showing aplurality of nozzle tray segments;

FIG. 5D is a sectional view of a portion of the feed distribution unitof FIG. 5B as seen along the lines 5D-5D of FIG. 5B;

FIG. 5E is a side view of a truss bearing a plurality of nozzle traysegments, as seen along the lines 5E-5E of FIG. 5C;

FIG. 6A is a perspective view of a primary feed distribution unitshowing a primary deflector plate in relation to a nozzle tray,according to an embodiment of the present invention;

FIG. 6B is a perspective view of a mixing box in relation to a secondarydeflector plate of a secondary feed distribution unit, according to anembodiment of the present invention;

FIG. 6C is a schematic side view of a secondary feed distribution unitincluding a secondary deflector plate, according to an embodiment of thepresent invention;

FIG. 6D is a schematic sectional side view of a secondary deflectorplate in relation to a riser on a collection tray, according to anembodiment of the present invention;

FIG. 7A is a schematic plan view of a mixing box, and FIG. 7B is aschematic plan view of the separated halves of the mixing box of FIG.7A, according to another embodiment of the present invention;

FIG. 7C is a perspective view of one half of a mixing box disposed on acollection tray segment of a secondary feed distribution unit, accordingto another embodiment of the present invention;

FIG. 8 is a schematic plan view of a portion of a nozzle tray showing anarray of fluid distribution nozzles, according to an embodiment of thepresent invention;

FIG. 9A shows a fluid distribution nozzle as seen from the side,according to an embodiment of the present invention; FIG. 9B is alongitudinal sectional view of the nozzle as seen along the lines 9B-9Bof FIG. 9A; and FIG. 9C shows liquid inlets in the nozzle along thelines 9C-9C of FIG. 9A;

FIG. 10 is a schematic plan view of a portion of a nozzle tray showingan array of fluid distribution chimneys, according to an embodiment ofthe present invention;

FIG. 11A shows a fluid distribution nozzle as seen from the side; FIG.11B is a longitudinal sectional view of the nozzle of FIG. 11A as seenalong the lines 11B-11B; FIG. 11C is a plan view of the nozzle of FIG.11A along the lines 11C-11C; and FIG. 11D shows a curved liquid inlet inthe nozzle body along the lines 11D-11D of FIG. 11A, according to anembodiment of the present invention;

FIG. 12A is a front view of a fluid distribution chimney; FIG. 12B is aside view of the chimney of FIG. 12A; and FIG. 12C is a longitudinalsectional view of the chimney of FIG. 12A showing the nozzle of FIG. 11Ainserted therein, according to another embodiment of the presentinvention;

FIG. 13 is a schematic longitudinal sectional view of a fluiddistribution nozzle, according to another embodiment of the presentinvention;

FIG. 14A is a schematic cut-away side view of a portion of a reactorshell showing a catalyst support unit in relation to a feed distributionunit; FIG. 14B is a plan view of the catalyst support unit as seen alongthe lines 14B-14B of FIG. 14A and showing a plurality of screen panels;FIG. 14C is a plan view of the catalyst support unit of FIG. 14B withthe screen panels removed and showing a plurality of grid panels; FIG.14D is a plan view of a portion of the catalyst support unit of FIG. 14Bwith the screen panels and grid panels removed and showing a pluralityof catalyst support beams; FIG. 14E is a sectional view showing thecatalyst support beams, grid panels and screen panels, as seen along thelines 14E-14E of FIG. 14B; and FIG. 14F is a sectional view showing thecatalyst support beams in relation to the reactor shell and shell ledge,as seen along the lines 14F-14F of FIG. 14D, according to the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides reactor internal apparatus for the evendistribution of fluids for downflow multi-bed catalytic reactors. Suchreactors may be used in the chemical and petroleum refining industriesfor effecting various reactions such as catalytic dewaxing,hydrotreating, hydrofinishing and hydrocracking. The present inventionis particularly useful for effecting mixed-phase reactions between aliquid, such as a liquid hydrocarbon feed and a gas, such as hydrogengas. More particularly, the invention relates to systems and apparatusfor improving the mixing and distribution of gas and liquid phases abovea bed of solid catalyst, while at the same time minimizing the height ofthe reactor internals. The instant invention is particularly useful forcatalytic reactors in which gas-liquid mixtures are passed through aplurality of beds of solid catalyst particles in a broad range ofprocesses, particularly for downflow catalytic reactors used forhydrotreating and hydrocracking in oil refining operations.

Unless otherwise specified, the recitation of a genus of elements,materials, or other components from which an individual or combinationof components or structures can be selected is intended to include allpossible sub-generic combinations of the listed components and mixturesthereof. Also, “include” and its variants are intended to benon-limiting, such that recitation of items in a list is not to theexclusion of other like items that may also be useful in the materials,elements, structures, compositions, and methods of this invention.

With reference to the drawings, FIG. 1 is a block diagram schematicallyrepresenting a reactor system 10, according to an embodiment of thepresent invention. Reactor system 10 may comprise a reactor shell 30having reactor shell walls which may be at least substantially vertical.Reactor shell 30 may house at least one catalytic unit 100 (see, e.g.,FIG. 2). In an embodiment, reactor system 10 may comprise a plurality ofcatalytic units, as represented in FIG. 1 as a first (1^(st)) catalyticunit 100 a and an n^(th) catalytic unit 100 n. The number of catalyticunits 100 within reactor shell 30 may typically be in the range from one(1) to about eight (8), e.g., n may be in the range from about two (2)to eight (8).

FIG. 2 is a block diagram schematically representing a catalytic unit100 for a reactor system 10, according to the present invention. In anembodiment, catalytic unit 100 may comprise a feed distribution unit200/200′, a catalyst support unit 400, and a catalyst bed 402. The feeddistribution unit may be a primary feed distribution unit 200′ (see,e.g., FIG. 4A) or a secondary feed distribution unit 200 (see, e.g.,FIG. 4B). In an embodiment, feed distribution unit 200/200′ may bedisposed above an associated catalyst bed 402, and catalyst bed 402 maybe supported on or by catalyst support unit 400. In an embodiment,catalyst bed 402 may comprise a layer of solid catalyst.

FIG. 3 is a block diagram schematically representing a reactor system10, according to another embodiment of the present invention. Reactorsystem 10 may comprise a primary feed distribution unit 200′ and atleast one secondary feed distribution unit 200. In the embodiment ofFIG. 3, reactor system 10 may comprise a first secondary feeddistribution unit 200 a and an n^(th) feed distribution unit 200 n. Thenumber of secondary feed distribution unit s 200 within reactor shell 30may typically be in the range from one (1) to about eight (8). The totalnumber of primary and secondary feed distribution unit s 200′/200 withinreactor shell 30 may correspond to the number of catalytic units 100within reactor shell 30.

FIG. 4A is a block diagram schematically representing a primary feeddistribution unit 200′, according to an embodiment of the presentinvention. Primary feed distribution unit 200′ may comprise a primarydeflector plate 210 and a nozzle tray 260. Primary deflector plate 210may be disposed above nozzle tray 260. Primary deflector plate 210 mayhave a plurality of perforations therein (see, for example, FIG. 6A).Primary deflector plate 210 may be configured for allowing the passageof fluid through primary deflector plate 210 to nozzle tray 260. Nozzletray 260 may include a plurality of fluid distribution nozzles 600 (see,for example, FIG. 8). In an embodiment, primary deflector plate 210 maybe supported on fluid distribution nozzles 600.

FIG. 4B is a block diagram schematically representing a secondary feeddistribution unit 200, according to an embodiment of the presentinvention. Secondary feed distribution unit 200 may comprise a mixingbox 220, a collection tray 240, a secondary deflector plate 250 and anozzle tray 260. Mixing box 220 may be disposed on collection tray 240.Secondary deflector plate 250 may be disposed beneath collection tray240 and above nozzle tray 260. Secondary deflector plate 250 may includea first peripheral portion and a second peripheral portion each having aplurality of perforations therethrough (see, for example, FIG. 6B).Secondary deflector plate 250 may further include a central entireportion lacking perforations therein (see, for example, FIGS. 6B and6D). Nozzle tray 260 may include a plurality of fluid distributionnozzles (see, for example, FIG. 8). In an embodiment, secondarydeflector plate 250 may be supported on fluid distribution nozzles 600.

FIG. 5A shows a schematic cut-away view of a portion of a reactor 20including a reactor shell 30 having shell walls 32, according to anembodiment of the present invention. Reactor shell 30 may house aprimary feed distribution unit 200′ and at least one secondary feeddistribution unit 200. A catalyst bed 402 may be disposed beneath eachof primary feed distribution unit 200′ and secondary feed distributionunit(s) 200. Each catalyst bed 402 may be disposed on a catalyst supportunit 400 (see, for example, FIGS. 14A-F). Each of primary feeddistribution unit 200′, secondary feed distribution unit(s) 200, andcatalyst support unit 400 may be supported by the walls 32 of reactorshell 30. The shell walls 32 at the location of primary feeddistribution unit 200′, secondary feed distribution unit(s) 200, andcatalyst support unit(s) 400 may be at least substantially vertical.Each of primary feed distribution unit 200′, secondary feed distributionunit(s) 200, and catalyst support units 400 may be disposed at leastsubstantially orthogonal to shell walls 32.

FIG. 5B is a plan view of a secondary feed distribution unit 200, asseen along the lines 5B-5B of FIG. 5A. Secondary feed distribution unit200 may include a plurality of collection tray segments 242. Collectiontray segments 242 jointly define collection tray 240 (see, for example,FIG. 6C). Collection tray segments 242 may be reversibly affixed to eachother to allow for the convenient assembly and disassembly of collectiontray 240. In an embodiment, collection tray segments 242 may be affixedto each other via a plurality of pins, such as wedge pins (not shown).One collection tray segment 242 is shown in FIG. 5B as being removed toreveal a nozzle tray segment 262 (see, for example, FIG. 5C). It is tobe understood that secondary feed distribution unit 200 is not limitedto the configuration of collection tray segments 242 as shown in FIG.5B, but rather other numbers and configurations of collection traysegments 242 are also within the scope of the present invention.

FIG. 5C is a plan view of a portion of the secondary feed distributionunit 200 of FIG. 5B with collection tray segments 242 removed. Secondaryfeed distribution unit 200 further comprises a plurality of nozzle traysegments 262. Nozzle tray segments 262 jointly define nozzle tray 260(see, for example, FIGS. 8 and 10). In FIG. 5C, one of the nozzle traysegments 242 is shown as being displaced. Each of collection traysegments 242 and nozzle tray segments 262 may be supported by aplurality of trusses 302 (see, for example, FIG. 5D). Trusses 302 may inturn be supported by a support ring 34. Support ring 34 may be affixedto an inner surface 32 a of shell wall 32. In an embodiment, supportring 34 may comprise a plurality of brackets (not shown) configured forthe attachment of trusses 302. Each truss may span reactor shell 30.Although two (2) trusses 302 are shown in FIG. 5C, other numbers oftrusses 302 are also within the scope of the present invention.Typically, the number of trusses 302 spanning reactor shell 32 may be inthe range from one (1) to about six (6).

With further reference to FIG. 5C, support ring 34 may be affixed, e.g.,welded, to the inner surface 32 a of reactor shell wall 32, and supportring 34 may be disposed circumferentially thereon. In an embodiment,support ring 34 may comprise a metal skirt (not shown) having an uppershelf and a lower shelf, the upper and lower shelves configured forsupporting collection tray 240 and nozzle tray 260, respectively. Inanother embodiment, support ring 34 may comprise an upper ring and alower ring coaxial with, and vertically spaced from, the upper ring(neither of the upper ring nor the lower ring are shown); wherein eachof the upper ring and the lower ring may be affixed (e.g., welded) tothe inner surface 32 a of reactor shell wall 32.

With still further reference to FIG. 5C, nozzle tray segments 262 may bereversibly affixed to each other to allow for the convenient assemblyand disassembly of nozzle tray 260. In an embodiment, nozzle traysegments 262 may be affixed to each other via a plurality of pins, suchas wedge pins (not shown). It is to be understood that secondary feeddistribution unit 200 is not limited to the configuration of nozzle traysegments 262 as shown in FIG. 5C, but rather other numbers andconfigurations of nozzle tray segments 262 are also within the scope ofthe present invention.

FIG. 5D is a sectional view of a portion of secondary feed distributionunit 200 of FIG. 5B, as seen along the lines 5D-5D of FIG. 5B, showing apair of spaced apart trusses 302. Each truss 302 may comprise an upperflange 304 and a lower flange 306. A plurality of collection traysegments 242 may be disposed on, and supported by, upper flange 304. Aplurality of nozzle tray segments 262 may be disposed on, and supportedby, lower flange 306.

FIG. 5E is a side view of a truss 302 bearing a plurality of nozzle traysegments 262 on truss lower flange 306, as seen along the lines 5E-5E ofFIG. 5C. In an embodiment, truss 302 may be supported at each end by abracket (not shown) attached to support ring 34. In FIG. 5E, collectiontray segments 242 are shown as being removed from truss 302.

FIG. 6A is a perspective view of a primary deflector plate 210 inrelation to a nozzle tray 260 of a primary feed distribution unit 200′,according to an embodiment of the present invention. In an embodiment,primary deflector plate 210 may be at least substantially circular.Primary deflector plate 210 may typically have an area in the range fromabout 70% to 100% of the cross-sectional area of reactor shell 30, andoften from about 90% to 100% of the cross-sectional area of reactorshell 30. Typically, nozzle tray 260 may have an area in the range fromabout 95% to 100% of the cross-sectional area of reactor shell 30.Nozzles 600 (see, e.g., FIGS. 9A-C) are omitted from FIG. 6A for thesake of clarity of illustration. Both nozzle tray 260 and primarydeflector plate 210 may be disposed at least substantially orthogonal toreactor shell wall 32.

FIG. 6B is a perspective view of a mixing box 220 in relation to asecondary deflector plate 250 of a secondary feed distribution unit 200,according to an embodiment of the present invention. Collection tray 240is omitted from FIG. 6B for the sake of clarity of illustration.Secondary deflector plate 250 may be disposed beneath mixing box 220.Secondary deflector plate 250 may include a first peripheral portion 254a, a second peripheral portion 254 b, and a central entire portion 252.Each of first peripheral portion 254 a and second peripheral portion 254b may have a plurality of perforations 256 therethrough. In contrast,central entire portion 252 may at least substantially lack perforations,holes or voids therein. Secondary deflector plate 250 may be configuredfor the passage of liquid through perforations 256.

FIG. 6C is a schematic side view of a secondary feed distribution unit200, according to an embodiment of the present invention. Secondary feeddistribution unit 200 may include a collection tray 240 having an uppersurface 240 a, a mixing box 220 disposed on upper surface 240 a, asecondary deflector plate 250 disposed beneath collection tray 240, anda nozzle tray 260 disposed beneath secondary deflector plate 250.Secondary feed distribution unit 200 may further include a riser 244.Riser 244 may be at least substantially cylindrical and affixed to uppersurface 240 a of collection tray 240. Riser 244 may extend at leastsubstantially orthogonal to collection tray 240.

FIG. 6D is a schematic sectional side view of a secondary deflectorplate 250 in relation to a riser 244 on a collection tray 240, accordingto an embodiment of the present invention. Secondary deflector plate 250comprises central entire portion 252 having an entire surface andlacking any perforations, holes, or voids therein. Central entireportion 252 may be disposed between first and second peripheral portions254 a, 254 b of secondary deflector plate 250. In an embodiment, centralentire portion 252 may occupy an area greater than a cross-sectionalarea of riser 244. In a sub-embodiment, the area of central entireportion 252 may be delineated by the base of a frusto-conical volumedefined by a straight line extending at an angle, θ from collection tray240 at the location of the inner wall of riser 244 to secondarydeflector plate 250. Typically, 0 may be in the range from about 20° to70°, usually from about 30° to 60°, and often from about 40° to 50°. Thevertical clearance, C_(H) between secondary deflector plate 250 andcollection tray 240 may be typically in the range from about 25% to 50%of the diameter of riser 244. In another sub-embodiment, central entireportion 252 may occupy an area about twice (2×) to five times (5×) thecross-sectional area of riser 244.

FIG. 7A is a schematic plan view of a mixing box 220, and FIG. 7B is aschematic plan view of the separated halves of mixing box 220 of FIG.7A, according to an embodiment of the present invention. Mixing box 220may comprise a first half 220 a and a second half 220 b. First andsecond mixing box halves 220 a, 220 b may each include a coupling flange222 for joining or coupling first and second halves 220 a, 220 btogether. In an embodiment, first and second halves 220 a, 220 b may bereversibly affixed to each other at their coupling flanges 222 via aplurality of pins, such as wedge pins (not shown).

FIG. 7C is a perspective view of one half of a mixing box 220 disposedon a collection tray segment 242, according to another embodiment of thepresent invention. A riser 244 may be disposed on collection traysegment 242 beneath mixing box 220. Riser 244 may be disposed abovesecondary deflector plate 250. Riser 244 may include at least one baffle(not shown) disposed on an inner surface of riser 244. Only onecollection tray segment 242 is shown in FIG. 7C. In practice, aplurality of collection tray segments 242 jointly form collection tray240.

FIG. 8 is a schematic plan view of a portion of a nozzle tray 260including an array of fluid distribution nozzles 600, according to anembodiment of the present invention. Each nozzle 600 may be configuredfor the mixing and even distribution of fluid to a catalyst bed 402disposed beneath nozzle tray 260. The array of nozzles 600 on nozzletray 260 may have a triangular pitch with a nozzle spacing typically inthe range from about 5 to 10 inches, and often in the range from about 6to 8 inches. FIG. 8 represents only a portion of nozzle tray 260; inpractice nozzle tray 260 may include many more nozzles 600.

With reference to FIGS. 9A-9C, FIG. 9A shows a fluid distribution nozzle600 as seen from the side, according to an embodiment of the presentinvention. FIG. 9B is a longitudinal sectional view of nozzle 600 asseen along the lines 9B-9B of FIG. 9A. FIG. 9C shows liquid inlets 614in nozzle 600 as seen along the lines 9C-9C of FIG. 9A. Nozzle 600 maycomprise a nozzle body 602, a nozzle proximal end 600 a, a nozzle distalend 600 b, a plurality of gas inlets 612, and at least one liquid inlet614. Nozzle proximal end 600 a may be sealed with a nozzle cap 604. Inan embodiment, cap 604 may be integral, e.g., cast, with nozzle body602.

With reference to FIG. 9B, nozzle body 602 may comprise a proximal bodyportion 602 a, an intermediate body portion 602 b, and a distal bodyportion 602 c.

Proximal body portion 602 a defines a substantially cylindrical proximalvoid. Intermediate body portion 602 b defines a substantiallycylindrical intermediate void in fluid communication with the proximalvoid. Distal body portion 602 c defines a substantially cylindricaldistal void in fluid communication with the intermediate void. Theproximal void may have a first diameter, the intermediate void may havea second diameter, and the distal void may have a third diameter. Thefirst diameter may be substantially greater than the third diameter, andthe third diameter may be substantially greater than the seconddiameter.

Each gas inlet 612 may be disposed laterally at proximal body portion602 a. Each gas inlet 612 may be configured for the passage of gastherethrough into proximal body portion 602 a. Nozzle 600 may furthercomprise a gas nozzle 606. Gas nozzle 606 may be disposed substantiallyorthogonal to the walls of nozzle body 602 between proximal body portion602 a and distal body portion 602 c to define intermediate body portion602 b. In an embodiment, gas nozzle 606 may be integral with nozzle body602. In another embodiment, gas nozzle 606 may comprise a metal ringdisposed within and affixed to nozzle body 602.

Each liquid inlet 614 may be disposed laterally at distal body portion602 c.

Each liquid inlet 614 may be configured for the passage of liquidtherethrough. As can be seen, for example in FIG. 9C, each liquid inlet614 may be disposed tangentially to an inner surface 616 of distal bodyportion 602 c. In an embodiment, each liquid inlet 614 may be linear.

With further reference to FIG. 9C, each liquid inlet 614 may have aliquid inlet length, I_(L), and a liquid inlet width, I_(W). In anembodiment, a ratio (I_(L):I_(W)) of liquid inlet length, I_(L) toliquid inlet width, I_(W) may be in the range from about 2:1 to 5:1. Theliquid inlet length, I_(L) shown in FIG. 9C may represent a minimumlength of each liquid inlet 614, e.g., due to the tangential orientationof liquid inlets 614 with respect to nozzle body 602.

Each of liquid inlets 614 may be configured for forming a film of liquidon inner surface 616 of distal body portion 602 c, and each of liquidinlets 614 may be configured for promoting the spiral flow of liquid oninner surface 616 of distal body portion 602 c, wherein the flow ofliquid is in a direction distal to liquid inlets 614.

Nozzle 600 may further comprise a converging first frusto-conicalportion 608 in fluid communication with distal body portion 602 c.Nozzle 600 may still further comprise a diverging second frusto-conicalportion 610 distal to, and in fluid communication with, firstfrusto-conical portion 608. Nozzle 600 may still further comprise aplurality of indentations 620 located at distal end 600 b of nozzle 600.Indentations 620 may be configured to further promote the dispersion offluid emanating from nozzle distal end 600 b as an evenly dispersedspray, e.g., having a conical spray pattern.

FIG. 10 is a schematic plan view of a nozzle tray 260 including an arrayof fluid distribution chimneys 700, according to an embodiment of thepresent invention. Each chimney 700 may be fitted, e.g., retrofitted,with a fluid distribution nozzle 600′ (see, for example, FIGS. 11A-D,and 12A-C) for the efficient mixing and even distribution of fluid to acatalyst bed 402 disposed beneath nozzle tray 260. The array of chimneys700, and their associated nozzles 600′, arranged on nozzle tray 260 mayhave a triangular pitch with a chimney 700/nozzle 600′ spacing typicallyin the range from about 5 to 10 inches, and often in the range fromabout 6 to 8 inches. FIG. 10 represents only a portion of nozzle tray260; in practice nozzle tray 260 may include many more chimneys 700.

FIG. 11A shows a fluid distribution nozzle 600′ as seen from the side,according to an embodiment of the present invention. FIG. 11B is alongitudinal sectional view of nozzle 600′ of FIG. 11A as seen along thelines 11B-11B, FIG. 11C is a plan view of nozzle 600′ of FIG. 11A alongthe lines 11B-11B. FIG. 11D shows a liquid inlet 614′ in the nozzle bodyalong the lines 11D-11D of FIG. 11A. Nozzle 600′ may comprise a nozzlebody 602, a nozzle proximal end 600′a, a nozzle distal end 600′b, a gasinlet 612′, and at least one liquid inlet 614′. Nozzle 600′ may be sizedand configured for insertion in a fluid distribution chimney, forexample chimney 700, during retrofitting an existing, conventional fluiddistribution tray to provide a highly efficient nozzle tray for ahydroprocessing reactor, according to an embodiment of the instantinvention (see, e.g., FIGS. 12A-C).

With reference to FIG. 11B, nozzle body 602 may comprise a proximal bodyportion 602 a, an intermediate body portion 602 b, and a distal bodyportion 602 c.

Proximal body portion 602 a defines a substantially cylindrical proximalvoid. Intermediate body portion 602 b defines a substantiallycylindrical intermediate void in fluid communication with the proximalvoid. Distal body portion 602 c defines a substantially cylindricaldistal void in fluid communication with the intermediate void. Theproximal void may have a first diameter, the intermediate void may havea second diameter, and the distal void may have a third diameter. Thefirst diameter may be substantially greater than the third diameter, andthe third diameter may be substantially greater than the seconddiameter.

In an embodiment, gas inlet 612′ may comprise a proximal axial openingin nozzle body 602. Gas inlet 612′ may be configured for the passage ofgas therethrough into proximal body portion 602 a. Nozzle 600′ mayfurther comprise a gas nozzle 606. Gas nozzle 606 may be disposedsubstantially orthogonal to the walls of nozzle body 602 betweenproximal body portion 602 a and distal body portion 602 c to defineintermediate body portion 602 b. Nozzle 600′ may further comprise aconverging first frusto-conical portion 608 in fluid communication withdistal body portion 602 c. Nozzle 600 may further comprise a divergingsecond frusto-conical portion 610 distal to, and in fluid communicationwith, first frusto-conical portion 608.

FIG. 11C is a plan view of nozzle 600′ of FIG. 11A, as seen along thelines 11C-11C, showing gas nozzle 606 within nozzle body 602. In anembodiment, gas nozzle 606 may be integral with the nozzle body. Inanother embodiment, gas nozzle 606 may comprise a metal ring disposedwithin and affixed to nozzle body 602. Gas nozzle 606 may be disposedconcentrically with nozzle body 602.

FIG. 11D shows a liquid inlet 614′ in nozzle body 602. Liquid inlet 614′may be disposed laterally at distal body portion 602 c. Liquid inlet614′ may be configured for the passage of liquid therethrough intodistal body portion 602 c. In an embodiment, liquid inlet 614′ maycomprise a curved channel 615 disposed within the wall of nozzle body602. As can be seen, for example in FIG. 11D, an inner terminus ofcurved channel 615 may be disposed tangentially to an inner surface 616of distal body portion 602 c. In an embodiment, curved channel 615 maysubtend an angle, α in the range from about 60° to 180°, typically fromabout 70° to 170°, and often from about 80° to 160°. In an embodiment,curved channel 615 may have a substantially rectangular cross-sectionalshape.

Liquid inlet 614′ may be configured for forming a film of liquid oninner surface 616 of distal body portion 602 c, and liquid inlet 614′may be configured for promoting the spiral flow of liquid on innersurface 616 of distal body portion 602 c, wherein the flow of liquid isin a direction distal to liquid inlet 614′.

Nozzle 600′ may still further comprise a plurality of indentations 620located at distal end 600 b of nozzle 600′. Indentations 620 may beconfigured to promote the dispersion of fluid emanating from nozzledistal end 600 b as an evenly dispersed spray, e.g., having a conicalspray pattern.

FIG. 12A is a front view of a fluid distribution chimney 700, FIG. 12Bis a side view of the chimney of FIG. 12A, and FIG. 12C is alongitudinal sectional view of the chimney of FIG. 12A with the nozzleof FIG. 11A inserted therein, according to another embodiment of thepresent invention. Chimney 700 may comprise a chimney wall 702, achimney proximal end 700 a, and a chimney distal end 700 b. Chimney wall702 may define a substantially cylindrical void therein. Chimney 700 maybe affixed to a nozzle tray 260 at chimney distal end 700 b. Chimneywall 702 may include a plurality of lateral holes 704/704′ therein. Inan embodiment, nozzle 600′ may be inserted within chimney700 such thatnozzle distal end 600′b protrudes distally beyond a lower surface 260 bof nozzle tray 260. Nozzle 600′ may be configured for alignment ofliquid inlet 614′ with at least one lateral hole 704. When inserted inchimney 700, nozzle 600′ may occlude and at least partially seal lateralholes 704′.

FIG. 12C is a longitudinal sectional view of chimney 700 having nozzle600′ (FIG. 11A) inserted therein. Chimney wall 702 may be affixed, e.g.,welded, to nozzle tray 260, and nozzle 600′ may be affixed, e.g.,welded, to chimney wall 702. Features and elements of nozzle 600′ aredescribed hereinabove, for example, with reference to FIGS. 11A-D.Nozzle 600′ when inserted within chimney wall 702 may serve to evenlymix and distribute fluids, e.g., a mixture of liquid feed and hydrogengas, to a catalyst bed in a reactor for petroleum refineryhydroprocessing reactions.

FIG. 13 is a schematic longitudinal sectional view of a fluiddistribution nozzle 800, according to another embodiment of the presentinvention. Nozzle 800 may comprise a substantially cylindrical hollownozzle body 802 having a proximal portion 802 a and a distal portion 802b, a cap 804 affixed to proximal portion 802 a, a base 808 affixed todistal portion 802 b, and a substantially cylindrical inner conduit 806disposed axially within proximal portion 802 a.

Cap 804 may have an axial proximal opening 805 therein, and innerconduit 806 may be disposed within proximal opening 805. Inner conduit806 may extend proximally beyond cap 804 to define a proximal end 806 aof inner conduit 806. Nozzle body 802 may have a plurality of outerslots 814 disposed circumferentially around nozzle body 802. A distalend 806 b of inner conduit 806 may terminate distally at a locationproximal to a distal end 814 b of each of outer slots 814.

Each of cap 804 and base 808 may be at least substantially dome-shaped,wherein cap 804 tapers distally from narrow to broad, and base 808tapers distally from broad to narrow. Each of cap 804 and base 808 maybe threaded. Cap 804 may be sealingly engaged with nozzle body 802 viathreads on proximal portion 802 a. Base 808 may be sealingly engagedwith nozzle body 802 via threads on distal portion 802 b. Base 808 mayhave an axial distal opening 810 configured for the passage anddistribution of fluid therethrough.

Inner conduit 806 may be sealingly engaged with cap 804 and disposedsubstantially concentrically with nozzle body 802. Nozzle body 802 andinner conduit 806 may jointly define a void within nozzle 800, whereinthe void may comprise an annular proximal void 803 a and a substantiallycylindrical distal void 803 b. Inner conduit 806 may have a plurality ofinner slots 812 disposed circumferentially around proximal end 806 a.The configuration of inner slots 812 and outer slots 814 may be at leastto some extent a matter of design choice for the skilled artisan.

Each of inner slots 812 may be in fluid communication with the void viainner conduit 806. Inner conduit 806 may be configured for the passageof gas therethrough from inner slots 812 to distal void 803 b. Nozzle800 may be configured for the passage of liquid through outer slots 814to distal void 803 b within nozzle body 802. Axial distal opening 810may be frusto-conical and taper distally from narrow to broad. Nozzle800 may be affixed to a nozzle tray 260, e.g., at distal portion 802 b.

In an embodiment, fluid distribution nozzle 800 may provide an efficientfluid mixing and distribution nozzle for a nozzle tray of a reactor,wherein nozzle 800 may be easily and inexpensively assembled usingoff-the-shelf pipe parts. In an embodiment, components of nozzle 800,e.g., nozzle body 802, cap 804 and base 808, may be constructed fromthreaded, standard stainless steel pipe, e.g., having National PipeThread (NPT) threads according to ANSI/ASME standard B1.20.1.

FIG. 14A is a schematic cut-away side view showing a portion of areactor 20, according to another embodiment of the present invention.Reactor 20 may house a primary feed distribution unit 200′, a secondaryfeed distribution unit 200, and a catalyst support unit 400. Primaryfeed distribution unit 200′ and secondary feed distribution unit 200 mayeach comprise elements, features, and characteristics as describedhereinabove, e.g., with reference to FIGS. 4A-13.

Reactor 20 may comprise a reactor shell 30. At least a portion ofreactor shell 30 may have substantially vertical shell walls 32. Each ofcatalyst support unit 400, primary feed distribution unit 200′, andsecondary feed distribution unit 200 may be disposed at leastsubstantially horizontally and orthogonal to the walls of reactor shell30. Only two catalyst support units 400, one primary feed distributionunit 200′, and one secondary feed distribution unit 200 are shown inFIG. 14A. In an embodiment, reactor 20 may house a plurality ofsecondary feed distribution units 200. Each secondary feed distributionunit 200 may have a corresponding catalyst support unit 400 forsupporting a catalyst bed 402 disposed beneath each secondary feeddistribution unit 200 (see, for example, FIG. 5A). Each catalyst supportunit 400 may comprise a plurality of catalyst support beams 406, aplurality of screen panels 408, and a plurality of grid panels 410.Catalyst beds 402 are omitted from FIGS. 14A-F for the sake of clarityof illustration.

FIG. 14B is a plan view of reactor shell 30, as seen along the lines14B-14B of FIG. 14A, and shows components of catalyst support unit 400including a plurality of catalyst support beams 406 and a plurality ofscreen panels 408. Each of catalyst support beams 406 may span reactorshell 30. Screen panels 408 may jointly define a catalyst screen whichmay occupy at least substantially 100% of the cross-sectional area ofreactor shell 30. With further reference to FIG. 14B, one screen panel408 is shown as being displaced to reveal a grid panel 410.

FIG. 14C is a plan view of the catalyst support unit 400 of FIG. 14Bwith all screen panels 408 removed and showing a plurality of gridpanels 410. Grid panels 410 may be supported by catalyst support beams406. Screen panels 408 may in turn be supported by grid panels 410.Peripherally located grid panels 410 having an arcuate outer edge may bejointly supported by catalyst support beam 406 and a circumferentialshell ledge 404. Each catalyst support beam 406 may comprise a pair oflateral support bars 414 (see, for example, FIG. 14E). Three grid panelsare shown in FIG. 14C as being removed to reveal portions of shell ledge404 and support bars 414.

With further reference to FIGS. 14B and 14C, it is to be understood thatcatalyst support unit 400 is not limited to the configuration of gridpanels 410 and screen panels 408 as shown in FIGS. 14B and 14C, butrather other numbers and configurations of both grid panels 410 andscreen panels 408 are also within the scope of the present invention. Inan embodiment, components of catalyst support unit 400 may be readilyassembled and disassembled. In a sub-embodiment, components of catalystsupport unit 400 may be affixed to each other via a plurality of pins,e.g., wedge pins (not shown).

FIG. 14D is a plan view of a portion of catalyst support unit 400 withboth screen panels 408 and grid panels 410 removed to more fully revealcatalyst support beams 406 and shell ledge 404. In an embodiment, shellledge 404 may comprise weld build-up material on an inner surface 32 aof shell walls 32. Although FIG. 14D shows two catalyst support beams406, the invention is by no means limited to two such beams per catalystsupport unit 400. In an embodiment, each catalyst support unit 400 maytypically comprise from about two (2) to six (6) catalyst support beams406.

FIG. 14E is a sectional view showing the catalyst support beams 406,grid panels 410, and screen panels 408, as seen along the lines 14E-14Eof FIG. 14B; and FIG. 14F is a sectional view showing a catalyst supportbeam 406 in relation to the reactor shell wall 32 and shell ledge 404,as seen along the lines 14F-14F of FIG. 14D. As noted hereinabove,catalyst support beams 406 may each comprise a pair of lateral supportbars 414. Support bars 414 may be configured for supporting at least aportion of each grid panel 410. The plurality of grid panel 410 may inturn jointly support the plurality of screen panels 408. The pluralityof screen panels 408 may jointly form a screen configured for spanningsubstantially the entire cross-sectional area of reactor shell 30, andthe plurality of screen panels 408 may be jointly configured forsupporting a catalyst bed 402 (see, e.g., FIG. 5A). Each catalyst bed402 may comprise a layer of particulate solid catalyst, as is well knownto the skilled artisan.

Numerous variations of the present invention may be possible in light ofthe teachings and examples herein. It is therefore understood thatwithin the scope of the following claims, the invention may be practicedotherwise than as specifically described or exemplified herein.

What is claimed is:
 1. A fluid distribution nozzle, comprising: (a) asubstantially cylindrical nozzle body having a plurality of outer slotsdisposed circumferentially around the nozzle body; (b) a cap affixed toa proximal portion of the nozzle body, the cap having an axial proximalopening therein; (c) a base affixed to a distal portion of the nozzlebody, the base having an axial distal opening therein; and (d) asubstantially cylindrical inner conduit disposed axially within theproximal portion of the nozzle body, the inner conduit disposed withinthe proximal opening of the cap, and the inner conduit extendingproximally from the cap to define a proximal end of the inner conduit,the inner conduit having a plurality of inner slots disposedcircumferentially around the proximal end of the inner conduit, and adistal end of the inner conduit terminating distally at a locationproximal to a distal end of each of the outer slots.
 2. The fluiddistribution nozzle of claim 1, wherein: (a) the axial distal opening isfrusto-conical and tapers distally from narrow to broad, (b) each of thecap and the base is threaded, (c) the cap is sealingly engaged with thenozzle body via threads on the proximal portion of the nozzle body, and(d) the base is sealingly engaged with the nozzle body via threads onthe distal portion of the nozzle body.
 3. The fluid distribution nozzleof claim 1, wherein: (a) the inner conduit is disposed substantiallyconcentrically with the nozzle body, (b) the inner conduit is sealinglyengaged with the cap, (c) the nozzle body, and the inner conduit jointlydefine a void within the device, (d) each of the inner slots is in fluidcommunication with the void via the inner conduit, (e) the voidcomprises an annular proximal void and a substantially cylindricaldistal void, (f) the inner conduit is configured for the passage of gastherethrough from the inner slots to the distal void, and (g) the deviceis configured for the passage of liquid through the outer slots into thenozzle body.